Method for producing hydrolysed keratinaceous material

ABSTRACT

The invention relates to a method for producing digestible keratinaceous material comprising the steps of hydrolysing keratinaceous material in the presence of water in a hydrolyser at elevated temperature and at a pressure between about 2 bar and about 15 bar, and drying the resultant hydrolysed keratinaceous material comprising at least partly insoluble material in a dryer at a temperature/time/pressure combination which limits the drop in pepsin and/or ileal digestibility by less than 10%, and/or such that the pepsin and/or ileal digestibility remains higher than 85%, or such that the pepsin and ileal digestibility remains higher than respectively 75% and 85%. Preferably, the drying of the resultant hydrolysed partly soluble keratinaceous material is performed in a dryer at a temperature such that the keratinaceous material remains at a temperature below 90° C., preferably below 80° C.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional application from U.S. application Ser.No. 14/908,577, filed on 29 Jan. 2016, which is a 35 U.S.C. 371 NationalStage of PCT application number PCT/EP2014/066314 filed on 29 Jul. 2014,which claims priority from EP application number 13178511.5 filed on 30Jul. 2013, from U.S. application No. 61/881,537 filed on 24 Sep. 2013and from EP application number 14163922.9 filed on 8 Apr. 2014. Allapplications are hereby incorporated by reference in their entireties.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The invention relates generally to a method for producing hydrolysedkeratinaceous material, such as feather meal or meal from hair.

2. Description of the Related Art

As a source of keratinaceous material, animal feathers, hair, hoof,nails and the like can be used. Feathers are by-products from poultry,and hair is a by-product from pigs, cattle, sheep and the like. Alsohoofs or nails, that may be grinded, can be used as source ofkeratinaceous material. Such keratinaceous material has a high proteincontent, consisting of at least 17 amino acids. However, thiskeratinaceous material is hardly digestible for animals or humansbecause of the highly structured polypeptides, with the presence of many(di)sulphide bridges.

Many processes exist for producing (partly) hydrolysed keratinaceousmaterial like feathers or hair, in order to increase the digestibility.Known methods include hydrolysis under pressure while using steam,enzymatic hydrolysis or chemical hydrolysis with e.g. base, acid orother reactive agent.

The keratinaceous material generally is not completely hydrolysed tomono-amino acids to improve the digestibility. In many processes, theresultant product from the partial hydrolysis of the keratinaceousmaterial is partly insoluble in water, and may comprise a mixture ofliquid (dissolved) and solid (insoluble) material. Generally, thecombined product is converted to a dry solid material by a dryingtechnique. The resultant product generally is not fully digestible foranimals, according to for example the pepsin and/or ileal digestibilitytest. Further, it appears that such products can have anti-nutritionalcompounds, like lanthionine, in significant amounts.

Several examples of methods for producing partially hydrolysedkeratinaceous material like feather meal include U.S. Pat. Nos.5,772,968, 4,286,884 and 4,172,073. U.S. Pat. No. 4,172,073 is directedto the water soluble part of the hydrolysed feathers, and is thereforenot relevant for the product that is only partially soluble.

Other references exist, that use in addition to steam, also chemicalreactants that influence the chemical composition of the hydrolysedmaterial, and cause more complicated work-up processes, as one has tohandle the chemicals. Examples of these processes include WO2011/003015,that use oxidizing solutions at low pH, WO1990/01023 that additionallyuses hydrogenperoxide, U.S. Pat. No. 4,232,123 that describes an acidhydrolysis followed with an enzymatioc hydrolysis, and EP0499260 thatdescribes hydrolysis with sulphites.

BRIEF SUMMARY OF THE INVENTION

It is an object of the invention to provide a method for producinghydrolysed, partly soluble, solid keratinaceous material, with animproved digestibility.

It is another object of the invention to provide a method for producinghydrolysed, partly soluble, solid keratinaceous material, with arelatively low amount of anti-nutritional compounds like lanthionine.

This object is achieved by a method comprising the steps of partlyhydrolysing keratinaceous material in the presence of water withpressure and heat at a pressure below about 15 bar, preferably belowabout 10 bar, and drying the resultant partially hydrolysed productcomprising at least partly insoluble material in a dryer at atemperature/time/pressure combination which limits the drop in pepsinand/or ileal digestibility by less than 10%, and/or such that the pepsinand/or ileal digestibility remains higher than 85%.

Preferably, this object is achieved by a method comprising the steps ofpartly hydrolysing keratinaceous material in the presence of water withpressure and heat at a pressure below about 15 bar, preferably belowabout 10 bar, and drying the resultant partially hydrolysed productcomprising at least partly insoluble material in a dryer at atemperature/time/pressure combination which limits the drop in pepsinand/or ileal digestibility by less than 10%, wherein the pepsin andileal digestibility remain higher than respectively 75% and 85%.

As it is clear from the molecular weights of the hydrolysedkeratinaceous material, the hydrolysis is not a complete chemicalhydrolysis to mono-amino acids, but the hydrolysis comprises thehydrolysation of a substantial number of amide bonds in thepolypeptides.

The presence of water during the hydrolysation step is meant to be anyof liquid phase water, steam, or water absorbed in the keratinaceousmaterial.

Preferably, the drop in pepsin and/or ileal digestibility is less than7%, more preferably less than 5%, and/or preferably, the pepsin and/orileal digestibility remains about 90% or higher, more preferable, about92% or higher. In a further preferred embodiment, the pepsin and ilealdigestibility remain about respectively 80% and 90% or higher, morepreferable, about respectively 82% and 92% or higher.

In one embodiment the drying process comprises drying at reducedpressure, such that the temperature of the material remains at atemperature below about 90° C., preferably at a temperature of about 80°C. or lower, and more preferably at about 75° C. or lower, such as forexample between about 60 to about 75° C., or for example at atemperature of about 70° C. or lower.

In another embodiment, the drying process comprises effective turbulenceof the keratinaceous material in a flow of hot air, such as in afluidized bed dryer, ring type dryer, rotating drum dryer and the like(hereinafter denoted as “hot air dryer”). In such cases it is importantto limit the heat exposure to a minimum. Hence, during a short period oftime, e.g. about 60 sec, or about 30 sec, the material may be at atemperature of about 100° C., or about 120° C. Generally, the maximumtemperature with short time heat exposure will be about 150° C. orlower, or preferably about 120° C. or lower. A relatively hightemperature may be present when relatively low water is present, as thecombination of water and heat appears to be most damaging.

It is a further object of the invention to provide a hydrolysed partlysoluble keratinaceous material with an improved nutritional value forfeed applications.

This object is achieved by providing partly insoluble keratinaceousmaterial with an in vivo digestibility of the Total Nitrogen Matter ofmore than 80%, preferably of about 82% or higher, as measured oncecectomized roosters, which material comprises an amount of lanthionineof less than about 2 wt %.

Lanthionine is the dimer of cysteine with a single thio-bridge.Lanthionine is generally considered as an anti-nutritional compound, andappears to be formed upon drying the partly hydrolysed keratinaceousmaterial. As lanthionine is anti-nutritional, an animal uses asubstantial amount of energy to remove such a useless compound from thebody. Thereby, lanthionine is counterproductive with respect to thespecific aim of supplementing the partly hydrolysed keratinaceousmaterial to an animal.

Lanthionine is one of the most important antinutritional compounds inhydrolysed keratinaceous material. Another antinutritional compound isfor example lysinoalanine.

It is an important advantage of the present invention, that theformation of lanthionine is reduced compared to hydrolysed keratinaceousmaterial commonly available in the market, like feather meal.

With measuring the ileal and/or pepsin digestibility, and the amount oflanthionine that is formed during the heating step, the average skilledperson will be able to optimize drying conditions such that theadvantages of the present invention are achieved.

Preferably, the hydrolysis is performed under pressure, while usingsteam, in a continuous process. However, batch processes exist as well,and are equally applicable.

In one embodiment of the invention, the drying is preferably performedin a disc dryer, at a pressure below about 0.4 bar (abs), while heatingthe discs to a temperature lower than about 160° C., preferably lowerthan 140° C., even more preferably lower than 130° C.

In an alternative embodiment, the dryer is a hot air dryer, preferably afluidized bed dryer, keeping the temperature of the outlet gaseousstream below about 120° C., preferably during a period of less thanabout 10 min, and more preferably during a period of less than about 5min. Alternative hot air dryers are flash dryers or ring type dryers.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

The following is a description of certain embodiments of the invention,given by way of example only and with reference to the examples.

The method according to the present invention comprises the steps ofhydrolysing keratinaceous material under pressure with steam at apressure below about 15 bar, preferably below about 10 bar, and dryingthe resultant hydrolysed keratinaceous material in a way, such that thekeratinaceous meal has a very high digestibility.

One of the steps to achieve such high digestibility is, to keep thekeratinaceous material preferably at a temperature below about 120° C.,preferably below about 100° C., or below about 80° C. during the dryingstep. The upper value of the temperature is dependent on the time periodthat such high temperature is kept.

In one embodiment of the invention, the drying is performed at reducedpressure. Suitable pressures include a pressure below about 0.5 bar(abs), preferably about 0.4 bar or lower. At a pressure of e.g. 0.3 bar,water boils at about 70° C., and thereby the keratinaceous materiallargely remains at a temperature below the boiling temperature at acertain pressure. An even lower vacuum is also possible, but may havethe disadvantage that such low vacuum is relatively expensive to keep.Hence, the reduced pressure generally will be a pressure higher than 10mbar (abs), and preferably about 100 mbar or higher.

In order to allow an economical process, it is important that theequipment or plant for treating the keratinaceous material is able toprocess about 2 ton per hour or more, preferably between about 4 andabout 15 tons. In view of the required high amount of throughput,several drying techniques, like for example drying overnight in a stoveare impossible to use. Furthermore freeze drying is preferably notperformed, and such drying method preferably is excluded because this isrelatively expensive.

Hence, in the present invention, preferably, drying processes areexcluded that comprise non-stirred/non-moving drying. Non-stirred ornon-moving drying is understood to be a method wherein the keratinaceousmaterial stays substantially on a fixed place, like when an amount offeather meal is placed in an oven at e.g. 50° C. overnight to dry theproduct or when the product is placed in a freeze drying tunnel.

The keratinaceous material, like feather or hair, is generally wetbefore supplying the material to the hydrolyser. The amount of watergenerally is between about 30 and about 80 wt %, and more preferablybetween about 50 and about 75 wt %, and most preferably, between about65 wt % and about 75 wt %.

The keratinaceous material may be milled or crushed to reduce the size.Generally, size reduction for hair of pigs or cattle is not very useful.

The hydrolyser generally works at a pressure of about 15 bar or below,preferably about 10 bar or below, as higher pressure is increasinglycostly. The pressure generally is about 2 bar or higher. Higher pressureis preferred, to increase the degree and speed of hydrolysation. Hence,the pressure preferably is about 4 bar or higher, and even morepreferable, about 6 bar or higher. Generally, the pressure will be about9 bar or lower. The pressure is given as bar absolute.

The hydrolysis will be performed in a hydrolyser, generally called asteam-hydrolyser. The hydrolyser is essentially a stirred vessel, andmay be batch or continuous. The hydrolyser preferably allows acontinuous process, and is a stirred tube like vessel like an extruderor a vertical stirred vessel. Stirring preferably is done with a slowlypropelling screw type of mixer, paddles or the like.

The hydrolysis step generally will be performed for a period betweenabout 5 and about 180 min, preferably between about 10 and about 60 min.Lower pressure generally requires longer reaction times.

Hence, the time/pressure window in general would be between about 2 toabout 15 bar during about 5 min. to about 3 hr, preferably between about2 and about 10 bar, and more preferably between about 4 to about 9 barduring about 10 min to about 1 hr. The temperature follows from the(saturated) steam pressure. Thus, the temperature at about 2 bar isabout 120° C., 4 bar corresponds to 144° C., and 9 bar to 175° C., thetemperature at about 10 bar is about 180° C., and about 15 barcorresponds to about 200° C.

The steam may be directly injected, or may be used for indirect heating.Indirect heating may also be applied with hot oil coils. Ultimately, thepressure should be as required, and the amount of water preferably issuch, that saturated steam is present at the chosen pressure andtemperature. Preferably, the total amount of steam present is about 200gram of steam or more per kg of feather and more preferably 300 gram perkg of feather. More live steam can be used instead of indirect steam toincrease the degree of hydrolysis.

The hydrolysis with such technique always results in only a partialhydrolysis. Hence, the resulting mixture comprises oligo-peptides, andpolypeptides.

The hydrolysed keratinaceous material will be dried after the (partial)hydrolysis. This drying generally is done in a number of steps. Thefirst step comprises bringing the mixture leaving the hydrolyser toatmospheric pressure, while evaporating part of the water.

Optionally, it is possible to press part of the water from thekeratinaceous material to bring the water content—for example—from about55 wt % or higher to about 45 wt % or lower.

The water pressed from the keratinaceous material after the hydrolysisstep is generally referred to as stick water. The stick water generallycontains some fatty materials and sediments, which fatty material can beremoved by centrifugation if desirable.

Removing the fat from the crude stick water will enable the productionof a low fat keratinaceous material such as feather meal. The amount offat in the crude stick water may be for example 30% or more, like forexample about 50% or more of the total fat present in the crudefeathers. With centrifugation, most fat can be removed from the stickwater. In this way, about 30% or more, preferably about 50% or more ofthe total fat will be reduced. Generally, not all fat can be removed inthis way, and for example less than about 70% of the fat is removed.

The stick water (defatted or not-defatted) can be further concentratedby means of evaporators, such as for example multiple effect fallingfilms, rising films or whipped film evaporators, preferably at reducedpressure, using the hot vapours of the dryer in a combined heat recoverysystem. Such evaporation will raise the dry substance of the stickwaters from about 5 to 10% up to about 25 to 40%. This concentrate, richin solubilized and insoluble proteins can be re-injected into the dryer,and processed with the solid keratinaceous material.

In an alternative embodiment, the stick water can be dried as such usingsuitable drying methods. Suitable drying techniques include a pluralityof techniques, such as for example drum drying and spray drying. Whenspray drying is used, it is preferred to have the fatty materials andsediments removed from the stick water. The dried keratinaceous materialcan have suitable particle sizes with a D50 between about 50 μm to about2 mm, preferably between about 0.1 and about 1 mm. The product may begranulated to any suitable particle size. Such use of stick water hasthe advantage of providing a product with a very high digestibility,such as preferably more than about 95% ileal and/or pepsindigestibility, more preferably about 97% or more.

Therefore, the present invention also relates to a process for preparinghighly digestible keratinaceous material in powder (or dry) form, byhydrolyzing keratinaceous material as described, and separating a waterphase (or liquid phase) from solid keratinaceous material in a press,and drying the water (or liquid) phase to obtain a product in powderform, having an ileal and/or pepsin digestibility of more than about95%.

Further, the present invention relates to a process for preparing highlydigestible keratinaceous material in a dry form with a reduced fatcontent, by hydrolyzing keratinaceous material in the presence of water,in a hydrolyser with heat and at a pressure between about 2 bar andabout 15 bar, preferably between about 2 bar and about 10 bar,separating a liquid phase from solid keratinaceous material in a press,centrifuging the liquid phase to separate an aqueous phase containingsolubilized proteins, a fat phase and residual solids andreincorporating the defatted aqueous phase and the residual solids intothe keratinaceous material and further drying the material to produce alow fat highly digestible feather meal.

The resultant, still moist keratinaceous material needs to be dried to amoisture content of about 12 wt % or less, preferably about 8 wt % orless. Drying to an amount of water lower than about 3 wt % generally isnot necessary, but would not harm. Drying is most preferably performedtill a moisture content of about 4 to 8 wt %. The amount is statedrelative to the total product.

Drying appears to be a crucial step in the quality of the keratinaceousmaterial such as feather meal. It appears that common drying techniquescause the digestibility to be reduced considerably.

According to GePro, a company selling feather meal, flash drying (hotair drying) results in better in vitro digestibility. The ilealdigestibility was found to be less than 85%. The pepsin digestibilityabout 70% to about 80%. Yet, further improvement is aimed for.

The present inventors found that further improvement was possible, byusing for example a conventional disc dryer at reduced pressure andreduced temperature, or when for example using a fluidized bed dryer.

Thus, the present invention provides a method in which partly hydrolysedkeratinaceous material is provided with higher in vitro and/or in vivodigestibility.

With the method of the present invention, it is possible to obtainhydrolysed, partly insoluble keratinaceous material with a moisturecontent of less than about 8 wt % and an in vivo digestibility of theTotal Nitrogen Matter of about 80% or higher (digestibility measured oncecectomized roosters).

Preferably, the amount of lanthionine in the hydrolysed keratinaceousmaterial is about 2 wt % or less, preferably about 1.7 wt % or less, orpreferably about 1.5 wt % or less, more preferably about 1.2 wt % orless.

The hydrolysed keratinaceous material is at least partly insoluble inwater, when 1 gram is put in 2 ml of water particles and fibrousmaterial is seen with the eye.

In a quantitative test, the amount of insoluble material can bemeasured. Such a test can be performed by dissolving 100 g feather mealin 1000 mL of water by stirring for 15 minutes in water at 20° C. Themixture is filtered, the filtrate and solid material weighed and dried,and the dried material weighed.

In the quantitative test, the amounts of solids is about 60 wt % ormore, preferably about 80 wt % or more, and even more preferably about90 wt % or more.

The amount of soluble material according to this test may be about 1 wt% or more, like about 2, about 3 wt %, about 4 or about 5 wt %. In casethe stick water is processed separately, the amount of insolublematerial may be between 100-98 wt %.

Despite the low solubility in water, it is possible to measure themolecular weight distribution of at least part of the keratinaceousmaterial preferably in a solvent that is designed to dissolve proteinousmaterial better than water. The most commonly used method is HPLC withwater/acetonitril as a solvent with a trilfuoroacetic acid (TFA; 0.1 wt%) and a SEC a column. The keratinaceous material may be better soluble,or completely soluble in said solvent. The partially hydrolysed materialshows a broad peak. The molecular weight distribution is in this fieldgenerally not denoted as Mn/Mw, as not all material may be dissolved. Itis anyhow possible to state which part of the material measured in theHPLC has a certain molecular weight.

In a preferred embodiment of the invention, the dissolved part of thehydrolysed keratinacious material consists for about 70 wt % or more ofmaterial having a molecular weight of about 5000 dalton or less, andmore than 30 wt % of the materials has a molecular weight of about 1000dalton or less.

In another preferred embodiment, which may be combined with theembodiment in the preceding paragraph, the amount of material of amolecular weight higher than about 5000 dalton is about 10 wt % or more,preferably about 20 wt % or more.

After the partial hydrolysation, the hydrolysed keratinaceous materialis dried to a moisture content of about 12 wt % or lower, or of about 8%or lower, with a method allowing low heat damage. The low heat damageprovides for a low or absent reduction in digestible material, and thefinal pepsin and/or ileal digestibility is still higher than 85%.Preferably, the pepsin and ileal digestibility remain higher thanrespectively 75% and 85%. The final pepsin and/or ileal digestibilitymay be about 85% or higher, or 90% or higher.

The drying preferably is performed in a dryer at atemperature/time/pressure combination which limits the drop in pepsinand/or ileal digestibility by less than about 10%, and/or such that theileal and/or pepsin digestibility remains higher than about 90%. In afurther preferred embodiment, the pepsin and ileal digestibility remainabout respectively 80% and 90% or higher, more preferable, aboutrespectively 82% and 92% or higher.

Preferably, the drop in pepsin and/or ileal digestibility is about 7% orless, more preferably about 5% or less, and/or preferably, the ilealdigestibility remains about 90% or higher, more preferably, about 92% orhigher.

The further drying is preferably done at reduced pressure, or in afluidized bed dryer, such that the heat damage, measured as reduceddigestibility is such that the final product still has a pepsin andileal digestibility of more than respectively about 80% and 90%.

Achieving such low damage by heat is unprecedented in the production offeather meal, which production is already done for over 60 years (seee.g. U.S. Pat. No. 2,542,984).

One of the steps to achieve such high digestibility is, to keep thekeratinaceous material preferably at a temperature below about 120° C.,preferably below about 100° C., or below about 80° C. The upper value ofthe temperature is dependent on the time period that such hightemperature is kept.

In one embodiment of the invention, the drying is performed at reducedpressure. Suitable pressures include a pressure below about 0.5 bar(abs), preferably below about 0.4 bar. At a pressure of 0.3 bar, waterboils at about 70° C., and thereby the keratinaceous material largelyremains at a temperature below such temperature. An even lower vacuum isalso possible, but may have the disadvantage that such low vacuum isrelatively expensive to keep. Hence, the reduced pressure generally willbe a pressure higher than about 10 mbar (abs), preferably at about 100mbar or higher.

In another embodiment, the drying process comprises effective turbulenceof keratinaceous material, in a fluidized bed dryer, ring dryer or forexample a flash dryer. In such cases it is important to limit the heatexposure to a minimum. Hence, during a short period of time, e.g. about60 sec, or about 30 sec, the material may be at a temperature of about100° C., or about 120° C. Generally, the maximum temperature with shorttime heat exposure will be about 150° C. or lower, or preferably about120° C. or lower. A relatively high temperature may be present whenrelatively low water is present, as the combination of water and heatappears to be most damaging.

Hence, the temperature/time window may be between about 60 to about 150°C. and between about 30 sec to about 2 hr, being dependent on the damagedone by heating the moist keratinaceous material. Lower temperatureallows longer drying times, and require generally, reduced pressure.Higher temperatures require short drying times, and generally do notrequire reduced pressure.

The digestible keratinaceous material such as feather meal comprises atleast 17 amino acids, such as very valuable amino acids like cysteineand tyrosine.

Preferably, the amount of cysteine is about 2 wt % or more, morepreferably about 3 wt % or more, even more preferably about 4 to 5 wt %or more. The wt % is expressed as relative to the total protein content.

The dried product may be milled and/or agglomerated to a suitableparticle size. The particles generally are smaller than a few mm, andlarger than 20 μm, in order to have a free flowing powder that can beeasily processed. Generally, the particle size will be between 0.01 and2 mm.

The digestible keratinaceous material such as feather meal can be usedas feed, or feed supplement, such as for example for petfood and/or foraquaculture, or as additive in cosmetics.

Dried highly digestible feather meal is in particular very useful forfeed or feed additive, like as feed for fish and for shrimp. It canreplace expensive and non-sustainable fish meal in such aquaculturediets. Replacement of fish meal will depend on the species, andexemplary amounts include up to 40% in salmon feed and up to 75% inAfrican catfish. With the very good quality feather meal of the presentinvention, it is expected that even higher amounts of replacement ispossible.

The digestible keratinaceous material such as feather meal can be packedin small bags, big bags or shipped in bulk container.

Measurement Methods

The following methods were used in the examples, and are suitable asmethods to measure the parameters stated in the description and theclaims:

Weight percentage (wt %) moisture: the moist keratinaceous material isdried overnight in a vacuum stove at reduced pressure and with asiccative. The material is weighted before and after the drying step,and the amount of moisture is calculated with using the initial measuredweight as 100% while assuming that all the volatile material is water.

HPLC and Mw determination: Standard HPLC equipment can be used. Thesolvent for the keratinaceous material is MilliQ water, acetonitrile andtrifluoroacetic acid (TFA) at 0.1 wt %. As a column, a Tosoh BioscienceSilica Column TSK G2000 SWXL 5 μm and Tosoh Bioscience Guard ColumnTSK-Gel SWXL 7 μm can be used, or comparable columns. The mobile phaseis a trifluoroacetic acid 0.1 wt %, containing 15% acetonitrile (CH3CN).The recording is done with a UV detector at 214 nm. The column can becalibrated with a mixture of bacitracin, insulin, alpha-lacto-albumin,beta-lacto-globulin and tryptophan.

Solubility of the keratinaceous material is qualitatively determined bydissolving 1 gram of keratinaceous material in 2 ml water at 20° C. Thetransparency of the liquid is determined by the human eye.

In a quantitative test the solubility of the keratinaceous material canbe performed as follows: 100 g of feather meal is dissolved in 1000 mLof water by stirring for 15 minutes in water at 20° C. The mixture isfiltered over a 350 μm filter under pressure. The filtrate and thesolids on the filter are dried and their weight measured. In thisanalysis, one would correct for the moisture content of the materials,i.e. the moisture content of the feather meal should be measured aswell. Further, one should correct for the amount of soluble materialthat remains in the wet solids which are filtered out.

Pepsin digestibility is measured according to ISO 6655 (August 1997);0.02% pepsin.

Ileal digestibility (also named “Boisen digestibility”) is measuredaccording to S. Boisen, 2007 (“In vitro analysis for determiningstandardized ileal digestibility of protein and amino acids in actualbatches of feedstuffs and diets for pigs”; Livestock Science (2007)309:182-185.).

In vivo digestibility of the Total Nitrogen Matter has been determinedon cecectomized roosters, according to Johnson et al., 1998. “Effects ofspecies raw material source, ash content, and processing temperature onamino acid digestibility of animal by-product meals by cecectomizedroosters and ileally cannulated dogs” Journal of Animal Science;76:1112-1122.

The percentage of lanthionine (abbreviated as LAN in the examples) isdetermined with standard HPLC methods.

Further modifications in addition to those described above may be madeto the materials and methods described herein without departing from thespirit and scope of the invention. Accordingly, although specificembodiments have been described, these are examples only and are notlimiting upon the scope of the invention.

EXAMPLES Example 1 and Comparative Experiments A-C

In a hydrolyser, working at 7 bar and saturated steam, feathers fromchicken with a moisture content of 65 wt % were treated for 25 min. Thepartly hydrolysed fibre was brought to atmospheric pressure through alet-down valve, and the fibrous mass, containing about 55% of water waspressed in a screw press to remove water. The residual water in thefeather meal was about 45 wt %.

The partly hydrolysed feather meal was dried in a number of differentways, with a classical disc dryer at 170° C. (8 bar pressure steaminside the disc), for about 1 hr (Comp Exp A), and for about 0.8 hr(Comp Exp B) (both comparative experiments, according to the prior art),a hot air dryer (Comp Exp C) (using a temperature of the air of for 80sec at 270° C. and for 120 sec at 80° C.), and a disc dryer at 300 mbarpressure (abs) (Example 1). In the last mentioned drying method (forexample 1), the feather meal did not reach temperatures higher thanabout 70° C.

TABLE 1 characteristics of dried feather meal Comp Comp Comp Exp A Exp BExp C Example 1 Process Characteristic Hydrolyser Batch Contin- Contin-Continuous uous uous Dryer Disc; Disc; Hot Low temp disc 1 hr 0.8 hr air(vacuum) Meal quality Pepsin digestibility 54 64 74 85 Ilealdigestibility 74 81 84 93 Molecular weight <5000 84 88 82 85 <1000 57 4248 56 <500 45 27 29 42 Percentage LAN 2.3 2.2 Nd 1.3 Nd: not determined

The solubility of the feather meal obtained in example 1 was measured.100 g feather meal with a moisture content of 4.81 wt % was dissolved in1000 mL of water by stirring for 15 minutes in water at 20° C. Themixture was filtered over a 350 μm filter under pressure. The filtrate(923.5 g) and the solids on the filter were dried and their weightmeasured and were as follows: solids on filter (wet) 148.1 gr; solids onfilter dry: 90.54 g. The filtrate contained 3.42 g solid material.Hence, the moisture in the solid material (which was 57.56 g) contained0.21 g soluble product. Hence, from the 95.19 g dry feather meal, 3.63 g(3.42 g+0.21 g) was soluble. This amounts to 3.8 wt % relative to thefeather meal.

Example 2

In a batch hydrolyser, working at 7 bar and saturated steam, feathersfrom chicken with a moisture content of 70 wt % were treated for 25 min.The partly hydrolysed fibre was brought to atmospheric pressure througha let-down valve, and the fibrous mass contained 65% of water.

The partly hydrolysed feather meal was dried in a fluidized bed dryer.The inlet temperature of the hot air was 140° C.; the outlet temperaturewas about 85° C. The feather meal did not reach temperatures higher thanabout 80° C. for any substantial amount of time. Drying till a moisturecontent of about 7 wt % took about 8 min. The in-vivo digestibility ofthe Total Nitrogen Matter (TNM) measured on cecectomized roosters was80% and the in-vitro ileal digestibility of the TNM was 88%.

Example 3

In a continuous hydrolyser, working at 5 bars and saturated steam, mixedpoultry feathers, comprising chicken feathers and turkey feathers, witha moisture content of about 70% were treated for about 20 minutes at aflow rate of 4 tons/hour. At the outlet of the hydrolyser, the moisturecontent of the hydrolyzed feathers was 50-55% and the ileal and pepsindigestibility were respectively 95% and 88%. The hydrolyzed featherswere dried at reduced pressure in a disc dryer at 300 mbar pressure(abs) at a flow rate of 4 tons/hour. The ileal and pepsin digestibilityof the dried feather meal (2.5% moisture) were respectively 90% and 81%.The drop in pepsin and ileal digestibility in the drying step wastherefore less than 10%. The in-vivo digestibility test of this feathermeal on cecectomized roosters showed a digestibility of 83%. The amountof lanthionine was 1.66 wt %.

CONCLUSION

The examples are illustrative only, but the tests show that with thehydrolysis and drying as performed with the present invention, highlydigestible keratinaceous meal, like feather meal is obtained.

What is claimed is:
 1. Method for producing digestible keratinaceousmaterial, preferably from feather, hair, hoof or nails, comprising thesteps of hydrolysing keratinaceous material in the presence of water, ina hydrolyser with heat and at a pressure between about 2 bar and about15 bar, preferably between about 2 bar and about 10 bar, and drying theresultant hydrolysed keratinaceous material comprising at least partlyinsoluble material in a dryer at a temperature/time/pressure combinationwhich limits the drop in pepsin and/or ileal digestibility by less than10%, and/or such that the pepsin and/or ileal digestibility remainshigher than 85%, or which limits the drop in pepsin and/or ilealdigestibility by less than 10%, wherein the pepsin and ilealdigestibility remain higher than respectively 75% and 85%.
 2. Method forproducing digestible keratinaceous material, preferably from feather,hair, hoof or nails, comprising the steps of hydrolysing keratinaceousmaterial in the presence of water, in a hydrolyser with heat and at apressure between about 2 bar and about 15 bar, preferably between about2 bar and about 10 bar, and drying the resultant hydrolysedkeratinaceous material comprising at least partly insoluble material ina dryer at a temperature such that the keratinaceous material remains ata temperature below about 90° C., preferably below about 80° C.
 3. Themethod according to any one of claims 1-2, wherein the hydrolysis isperformed in a continuous hydrolyser.
 4. The method according to any oneof the preceding claims, wherein the keratinaceous material is suppliedto the hydrolyser with a moisture content of about 30 to about 80 wt %(relative to the weight of moisture plus keratinaceous material).
 5. Themethod according to any one of the preceding claims, wherein the dryeris a disc dryer processing at reduced pressure, preferably at a pressurebetween about 10 and about 500 mbar (abs), preferably between about 100and about 400 mbar.
 6. The method according to any one of claims 1-4,wherein the drying is performed in a flow of hot air such as in afluidized bed dryer, ring-type dryer, rotating flash dryers and thelike.
 7. The method according to any one of the preceding claims,wherein the dried digestible keratinaceous material has a moisturecontent of below about 12 wt %, preferably between about 4 and about 8wt %.
 8. The method according to any one of claims 2-7 wherein thedrying step is performed at a temperature/time/pressure combinationwhich limits the drop in pepsin and/or ileal digestibility by less thanabout 10%, and/or such that the pepsin and/or ileal digestibilityremains higher than about 85%, or which limits the drop in pepsin and/orileal digestibility by less than 10%, wherein the pepsin and ilealdigestibility remain higher than respectively about 75% and about 85%.9. The method according to any one of the preceding claims, wherein anamount of more than about 2 tons of keratinaceous material is processedper hour and the drying method is not a non-stirred/non-moving dryingmethod.
 10. The method according to any one of the preceding claims,wherein the drying step is performed at a temperature/time/pressurecombination which limits the drop in pepsin and/or ileal digestibilityby less than about 7%, preferably less than about 5%, and/or such thatthe pepsin and/ileal digestibility remains higher than aboutrespectively 80% and 90%, more preferably higher than about respectively82% and 92%.
 11. Hydrolysed, partly insoluble keratinaceous material,obtainable with the method of any one of claims 1-10, wherein thematerial has a moisture content of less than about 12 wt % and an ilealand pepsin digestibility of about respectively 75% and 85% or higher,preferably about respectively 80% and 90% or higher or an in vivodigestibility on cecectomized roosters of about 80% or higher,preferably about 82% or higher.
 12. Hydrolysed, at least partlyinsoluble, keratinaceous material according to claim 11, wherein thematerial has an amount of lanthionine of about 2.0 wt % or less,preferably about 1.5 wt % or less.
 13. Hydrolysed, partly insolublekeratinaceous material according to any one of claims 11-12, wherein thesoluble part of the hydrolysed keratinacious material comprisespolypeptides in an amount of more than about 70 wt % having a molecularweight of lower than about 5000 dalton, and more than 30 wt % smallerthan about 1000 dalton.
 14. Use of the hydrolysed, partly insolublekeratinaceous material according to any one of claims 11-13 as feedand/or feed additive, like in petfood or for aquaculture, or incosmetics.
 15. Process for preparing highly digestible keratinaceousmaterial in a dry form, by hydrolyzing keratinaceous material in thepresence of water, in a hydrolyser with heat and at a pressure betweenabout 2 bar and about 15 bar, preferably between about 2 bar and about10 bar, separating a liquid phase containing solubilized proteins fromsolid keratinaceous material in a press, and drying separately theliquid phase to obtain a product in powder form, having an ileal and/orpepsin digestibility of more than about 95%.
 16. Process for preparinghighly digestible keratinaceous material in a dry form with a reducedfat content, by hydrolyzing keratinaceous material in the presence ofwater, in a hydrolyser with heat and at a pressure between about 2 barand about 15 bar, preferably between about 2 bar and about 10 bar,separating a liquid phase from solid keratinaceous material in a press,centrifuging the liquid phase to separate an aqueous phase containingsolubilized proteins, a fat phase and residuals solids, reincorporatingthe defatted aqueous phase and the residuals solids into thekeratinaceous material and further drying the material to produce a lowfat highly digestible feather meal.